Evaporator with Service Clip Configurations

ABSTRACT

The present application provides an evaporator. The evaporator may include a housing, a fan module removably positioned within the housing, a number of retainer clips positioned on the fan module, and a number of retainer clip slots positioned on the housing. The retainer clips and the retainer clips slots may include a clip attachment configuration and a service clip configuration.

TECHNICAL FIELD

The present application relates generally to refrigeration systems and more particularly relates to a modular evaporator and components thereof for use within a walk-in cooler and other types of refrigeration systems and having a number of different service clip configurations.

BACKGROUND OF THE INVENTION

Modern air conditioning and refrigeration systems provide cooling, ventilation, and humidity control for all or part of an enclosure such as a building, a cooler, and the like. Generally described, the refrigeration cycle includes four basic stages to provide cooling. First, a vapor refrigerant is compressed within a compressor at high pressure and heated to a high temperature. Second, the compressed vapor is cooled within a condenser by heat exchange with ambient air drawn or blown across a condenser coil by a fan and the like. Third, the liquid refrigerant is passed through an expansion device that reduces both the pressure and the temperature of the liquid refrigerant. The liquid refrigerant is then pumped within the enclosure to an evaporator. The liquid refrigerant absorbs heat by blowing or drawing air across the evaporator coil as the liquid refrigerant changes to vapor. Finally, the vapor is returned to the compressor and the cycle repeats. Various alternatives on this basic refrigeration cycle are known and also may be used herein.

Conventional walk-in coolers, such as those typically found in the food service industry and the like, generally have an evaporator therein similar to that described above. The evaporator typically is hung from the ceiling of the cooler. The evaporator thus may take up space within the cooler that could have been used for storage or other purposes. The evaporator also may present a hazard in that the evaporator may extend downward into the usual standing area so as to present a risk of injury for individuals walking therein. Likewise, a condensate drain may hang below the evaporator. The condensate drain also may take up useful storage space and itself may be an injury risk.

Typical evaporators generally also require extensive disassembly so as to repair and/or replace a component therein such as a fan and the like. Such disassembly procedures generally involves shutting down the cooler and may involve transferring all of the items stored therein. Moreover, even repairs that do not involve shutting down the cooler at least require the workman to work in the refrigerated space for an extended period of time. Repairing an existing evaporator thus may be a somewhat costly and time intensive procedure. Similarly, installing a new evaporator may be difficult given the typical weight involved and the difficulty in maneuvering in the close spaces typically found therein.

There is a therefore a desire for an improved evaporator design for use within walk-in coolers and other types of refrigeration systems. Such an improved evaporator design preferably may take up less storage space therein and create less of an injury hazard while providing easy access thereto for repair and/or replacement of the components therein.

SUMMARY OF THE INVENTION

The present application and the resultant patent thus provide an evaporator. The evaporator may include a housing, a fan module removably positioned within the housing, a number of retainer clips positioned on the fan module, and a number of retainer clip slots positioned on the housing. The retainer clips and the retainer clips slots may include a clip attachment configuration and a service clip configuration.

The present application and the resultant patent further provide an evaporator. The evaporator may include a housing, a fan module removably positioned within the housing, a number of retainer clips positioned on the fan module, a number of retainer clip slots positioned on the housing, a service clip positioned on the fan module, and a service clip slot positioned on the housing. The retainer clips and the retainer clips slots may include a clip attachment configuration and the service clip and the service clip slot may include a service clip configuration.

The present application and the resultant patent further provide an evaporator. The evaporator may include a housing, a fan module removably positioned within the housing, a number of retainer clips positioned on the fan module, a number of retainer clip slots positioned on the housing, a support rail within the housing, and a number of support rail slots positioned within the support rail. The retainer clips and the retainer clips slots may include a clip attachment configuration and the retainer clips and the support rail slots may include a service clip configuration.

These and other features of the present application and the resultant patent will become apparent to one of ordinary skill in the art upon review of the following detailed description when taken in conjunction with the several drawings and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side plan view of an evaporator as may be described herein positioned within a cooler.

FIG. 2 is a side cross-sectional view of the evaporator of FIG. 1.

FIG. 3 is an exploded top perspective view of the components of the evaporator of FIG. 1.

FIG. 4 is an exploded bottom perspective view of the components of the evaporator of FIG. 1.

FIG. 5 is an exploded view of the components of a fan module that may be used in the evaporator of FIG. 1.

FIG. 6 is a partial perspective view of an alternative embodiment of an evaporator as may be described herein.

FIG. 7 is a partial perspective view of the evaporator of FIG. 6 with a removed fan module.

FIG. 8 is a partial perspective view of the fan module of FIG. 7 hung in a service clip configuration.

FIG. 9 is a bottom perspective view of the evaporator of FIG. 6.

FIG. 10 is a perspective of the evaporator of FIG. 6 with one fan module hung in an alternative embodiment of a service clip configuration.

FIG. 11 is a side plan view of the evaporator of FIG. 6 with the fan module hung in the service clip configuration of FIG. 10.

FIG. 12 is a perspective of the evaporator of FIG. 6 with one fan module hung in a further alternative embodiment of a service clip configuration.

DETAILED DESCRIPTION

Referring now to the drawings, in which like numerals refer to like elements throughout the several views, FIGS. 1-4 show an evaporator 100 as may be described herein. The evaporator 100 may be positioned within a cooler 110. The evaporator 100 typically is positioned on a ceiling 115 thereof. The cooler 110 may be any type of chilled enclosure and may include refrigerators, freezers, or any structure chilled below typical ambient temperatures. The cooler 110 may have any desired size, shape, or configuration. The evaporator 100 described herein is in no way limited by the type or design of the cooler 110. A drain line 120 may extend from the evaporator 100 to the exterior of the cooler 110. The drain line 120 may have any desired size, shape, or configuration. The evaporator 100 may be in communication with other types of refrigeration equipment such as the components of the refrigeration cycle described above and the like. The overall evaporator 100 may be modular in nature as will be described in more detail below such that the components thereof may be easily installed and replaced. An example of such an evaporator 100 is shown in commonly owned U.S. Patent Application Publication Nos. 2012/0152502 A1 and 2012/0152499. U.S. Patent Application Publication Nos. 2012/0152502 A1 and 2012/0152499 are incorporated herein by reference in full.

The evaporator 100 may include a housing 130. The housing 130 may be made in whole or in part out of molded plastics. Metals and other types of substantially rigid materials also may be used as the panel and/or as a backbone-type structure. The housing 130 may include a top panel 140, a drain pan 150, and a pair of side panels 160. The top panel 140 may include a number of mounting brackets 170 attached thereto. The mounting brackets 170 may extend from one end of the top panel 140. The top panel 140 also may have a number of mounting apertures 180 positioned therein. The mounting brackets 170 and the mounting apertures 180 may have any size, shape, or configuration. The evaporator 100 may be attached to the ceiling 115 of the cooler 110 or other structure via the mounting brackets 170 and the mounting apertures 180 as well as conventional types of fasteners such as bolts and the like.

The drain pan 150 may have one or more drain channels 190 formed therein. The drain channels 190 may lead to a drain pipe 200 on one end thereof. The drain pipe 200 may extend outwardly and slightly downwardly from the drain pan 150. The drain pipe 200 may be in communication with the drain line 120. The drain pan 150 also may have a degree of slope itself leading to the drain pipe 200. The drain pan 150 also may include a raised lip 210 positioned about a periphery thereof. The raised lip 210 permits the drain pan 150 to catch water droplets on the exterior thereof. A submersible pump also may be used herein. Other configurations and other components may be used herein.

The side panels 160 may include a service access panel 220 and a non-service access panel 230. The service access panel 220 provides access to the refrigeration components as will be described in more detail below as well as an electrical module 240. The electrical module 240 includes all of the electrical components and controls for the operation of the overall evaporator 100. The electrical module 240 and the other electrical components of the overall evaporator 100 may be prewired for easy installation. A high voltage barrier panel 250 may surround the electrical module 240. A wiring diagram or other types of information may be positioned about the service access panel 220. The service access panel 220 and the non-service access panel 230 may be hinged for access thereto. Other configurations and other components may be used herein.

A coil assembly 260 may be mounted onto the top panel 140 or otherwise. The coil assembly 260 may include a number of tubes 270 with a number of spaced fins 280. The tubes 270 may extend through a pair of end plates 290. The tubes 270 and the fins 280 may be made out of copper, aluminum, or other types of substantially rigid materials with good heat transfer characteristics. The fins 280 may be corrugated. Other configurations and other components may be used herein.

The coil assembly 260 may be in communication with a refrigeration tubing/piping 320. The refrigeration tubing/piping 320 may have any desired size, shape or configuration. The refrigeration tubing/piping 320 may be in communication with other types of refrigeration components such as those described above and the like. Other components and other configurations may be used herein.

The evaporator 100 also may include a fan module 330 as is shown in FIG. 5. The fan module 330 may include a fan housing 340. The fan housing 340 may be made out of molded plastics, metals, and other types of substantially rigid materials. The fan housing 340 may have a number of mounting rails 350 positioned thereon. The mounting rails 350 may mate with a number of top panel rails 360 positioned about the top panel 140. The use of the mounting rails 350 and the top panel rails 360 allows the fan module 330 as a whole to slide in and out of the housing 130 of the evaporator 100 as a whole. A fan wiring harness 365 and the like may extend along the top panel rails 360 and/or otherwise within the housing 130 and may be in communication with the fan module 330 and the electrical module 240 and/or other controls as the fan module 330 slides therein.

The fan housing 340 also may include a locking member 370 positioned thereon. The locking member 370 may be biased into the locked positioned. The locking member 370 may mate with a receiving member 380 positioned about the top panel 140 or otherwise (including the reverse). When the fan module 330 is slid into the housing 130 of the evaporator 100, the locking member 370 and the receiving member 380 may cooperate to lock the fan module 330 into place. Other types of locking mechanism may be used herein.

The fan module 330 may include a fan assembly 385 mounted within the fan housing 340. The fan assembly 385 may have a fan 390 mounted on a fan mounting bracket 395. The fan 390 may be a backward incline centrifugal fan and the like. The backward incline centrifugal fan may have an overall reduced height as compared to conventional axial refrigeration fans. A backward incline centrifugal fan generally is used in air handlers as opposed to refrigeration units due to the ability of the fan to overcome high static pressure loads associated with duct work. The fan 390 may be a variable speed fan. The fan 390 pulls the airflow through the coil assembly 260 and turns the flow into the cooler 110 or other refrigerated space. The fan assembly 385 also may include a fan motor 400, one or more air plenums 410, and electronics and other controls. The electronics and the other components may be placed in communication with the electrical module 240 via the wiring harness 365 via one or more quick disconnect fittings or otherwise. Other types of fans 390, fan motors 400, and controls may be used herein. A replaceable venture ring may be positioned about the fan 390. Other components and other configurations may be used herein.

The fan module 330 also includes a grill 420 so as to enclose one end of the housing 340. The grill 420 may be made out of molded plastics, metals, and other types of substantially rigid materials. The grill 420 may have any size, shape, or configuration. The grill 420 may be attached by a number of clips or other attachment means for easy access thereto and for easy cleaning.

In use, the evaporator 100 may be attached to the ceiling 115 of the cooler 110 or other type of structure. A template may be used to align the location of the mounting brackets 170 and the mounting apertures 180 so as to drill the appropriate holes and the like. Advantageously, the fan module 330 need not be positioned within the housing 130. Removing the fan module 330 makes the overall evaporator 100 lighter and makes attachment to the cooler 110 considerably easier than may be possible with known units. The coil assembly 260 and the electrical module 240 with the related wiring may be premounted to the housing 130. Once the housing 130 is installed, the fan module 330 may be slid within the housing 130 via the mounting rails 350 and the top panel rails 360. The electronics and other controls are prewired such that communication with the electrical module 340 is established as the fan module 330 slides therein. Multiple fan modules 330 may be used in a single housing 130.

Access to the electrical module 340 and the coil assembly 260 may be provided via the service access panel 220. Likewise, the fan module 330 may be quickly and easily removed from the housing 130 for repair, replacement, and/or cleaning. For example, removing the fan module 330 provides access for coil cleaning, drain pan cleaning, and the like. The fan module 330 may be slid out to an intermediate position or a retracted position or the locking member 370 may be released such that the fan module 330 may be removed completely. The fan module 330 thus may have at least an installed position, a retracted position, and a removed position. Advantageously, the fan module 330 may be removed from the housing 130 of the evaporator 100 and repaired outside of the cooler 110.

The evaporator 100 thus provides ease of installation and ease of access with a relatively low profile. For example, if existing evaporators are generally in excess of a height of about fourteen (14) inches (about 35.56 centimeters), the evaporator described herein may be about eleven (11) inches (about 27.94 centimeter) or so. These dimensions are for the purpose of comparison only and any height may be used herein. Nonetheless, the evaporator 100 described herein provides more storage room for the cooler 110 given the reduced profile. Likewise, the risk of injury also may be reduced herein.

FIGS. 6 and 7 show an alternative embodiment of an evaporator 500 as may be described herein. The evaporator 500 may be similar to the evaporator 100 described above. The evaporator 500 may include an elongated housing 510. The housing 510 may be sized for a number of fan modules 520. Any number of fan modules 520 may be positioned within the housing 510. The fan modules 520 likewise may include a fan housing 530 with a fan assembly 540 therein. The fan assembly 540 may include a fan 550, a fan motor 560, and a wiring harness 570. The fan 550 and the fan motor 560 may be supported by a fan bracket 580. Other components and other configurations may be used herein.

Instead of sliding the fan module 330 into the housing 130 along the mounting rails 350, 360 and locking the fan modules 330 in place via the locking member 370 and the receiving member 380 as is described above, the evaporator 500 herein may use a clip attachment configuration 590. The clip attachment configuration 590 may include a number of retainer clips 600. The retainer clips 600 may extend from a first end 610 of the fan bracket 580 or from elsewhere along the fan housing 530. Although two (2) retainer clips 600 are shown, any number of the retainer clips 600 may be used herein. The retainer clips 600 may have a substantial U-like shape 620 when viewed from the side including a substantially vertical member 630 and a substantially horizontal member 640. Other sizes, shapes, and configurations may be used herein.

The clip attachment configuration 590 also may include an elongated locking member 650. The locking member 650 may extend from a second end 660 of the fan bracket 580 or from elsewhere along the fan housing 530. Although one locking member 650 is shown, any number of locking members 650 may be used herein. The locking members 650 may have a substantially inverted L-like shape 670 when viewed from the side with a substantially vertical member 680 and a substantially horizontal member 690. Other shapes, sizes, and configurations may be used herein.

The clip attachment configuration 590 also may include a number of retainer clip slots 700 positioned about a top panel 710 of the housing 510. The retainer clip slots 700 may be sized and shaped to conform to the shape of the horizontal members 640 of the retainer clips 600 so as to receive the retainer clips 600 therein. Both the retainer clips 600 and the top panel 710 may have a number of screw apertures 720 sized for screws or other types of retaining means. Other sizes, shapes, and configurations may be used herein.

The clip attachment configuration 590 also may include an elongated receiving member 730 positioned within the top panels 710 for receiving the locking member 650. The receiving member 730 may include a receiving member aperture 740 and a top panel indent 750. The aperture 740 may be sized to allow the horizontal member 690 of the locking member 650 to pass therethrough while the top panel indents 750 may be sized to support the horizontal member 690 therein. The clip attachment configuration 590 also may include a housing support rail extending along a bottom 770 of the housing 510. The support rail 760 may have any size, shape, or configuration. Other components and other configurations may be used herein.

In use, each fan module 520 may be inserted into the elongated housing 510. Specifically, the locking member 650 of the fan module 520 may be positioned within the receiving member 730 along the top panel 710 of the housing 510. The fan housing 530 may be supported on the housing support rail 760 at the bottom 770 of the housing 510. The retainer clips 600 may be positioned within the retainer clip slots 700. Screws or other types of retaining means may be positioned through the screw apertures 720 so as to secure the fan module 520 therein. The fan modules 520 likewise may be removed from the housing 510 by reversing these steps.

The evaporator 500 also may have a number of service clip configurations 800. As is shown in, for example, FIG. 8, the service clip configuration 800 may include a service clip 810. The service clip 810 may be attached to the fan motor 560 or elsewhere on the fan housing 530 and/or the fan assembly 540. The service clip 810 may have one or more angled members 820 and an elongated member 830 extending from a base 840. The angled members 820 may have any desired angle. The service clip 810 may have any size, shape, or configuration. Any number of the service clips 810 may be used herein. The service clip configuration 800 also may include a service clip slot 850 positioned about the top panel 710 of the housing 510. The service clip slot 850 may be sized to accommodate and receive the service clip 810. Other components and other configurations may be used herein.

In use, the fan module 520 may be removed from the elongated housing 510. The service clip configuration 800 allows the fan module 520 to be supported by the housing 510 after initial removal from the housing 510. As shown in FIG. 9, the service clip configuration 800 allows for easy “hands free” servicing and cleaning of the housing 510 and the components therein such as the drain pan 150, the coil assembly 260, the wiring harness 570, and the like while supporting the fan module 520 adjacent thereto. Once servicing is complete, the service clip 810 may be removed from the service clip slot 850 and the fan module 520 may be reinstalled within the elongated housing 510 as described above.

FIGS. 10 and 11 show an alternative embodiment of a service clip configuration 860. In this example, the service clip configuration 860 may use the retaining clips 600 as described above. The service clip configuration 860 also includes a number of support rail service clip slots 870 positioned about the housing support rail 760. The support rail service clip slots 870 may be sized and shaped so as to receive the retainer clips 600 therein in a vertical orientation. Other components and other configurations may be used herein.

In use, the fan module 520 may be removed from the housing 510 as described above. The fan module 520 may be rotated and hung on the support rail 760 via the retainer clips 600 inserted within the support rail service clip slots 870 in a vertical orientation. The housing 510 may be serviced and then the fan module 520 may be reinstalled.

FIG. 12 shows a further embodiment of a service clip configuration 880 as may be described herein. In this example, the service clip configuration 880 may use the retainer clips 600 and the retainer clip slots 700 of the top panel 710. The fan module 520 may be removed from the housing 510 as described above. The fan module 520 then may be rotated and hung vertically by the retainer clips 600 positioned in the retainer clip slots 700 in a vertical orientation. The fan module 520 thus may hang at an angle as is shown. The fan module 520 then may be reinstalled within the housing 510 as described above. Other components and other configurations may be used herein.

The service clip configurations 800 described herein thus allow for the temporary positioning of the fan modules 520 about the housing 510 while providing ample access for servicing the housing 520 and the components therein. The service clip configurations 800, 860, 880 and the like also have the advantage that the wiring harness 570 need not be detached so as to service the housing 510 or the fan module 520. This feature thus provides a considerable time savings as compared to complete removing the fan module 520 from the housing 510. Other components and other configurations may be used herein.

It should be apparent that the foregoing relates only to certain embodiments of the present application and the resultant patent. Numerous changes and modifications may be made herein by one of ordinary skill in the art without departing from the general spirit and scope of the invention as defined by the following claims and the equivalents thereof. 

We claim:
 1. An evaporator, comprising: a housing; a fan module removably positioned within the housing; a plurality of retainer clips positioned on the fan module; and a plurality of retainer clip slots positioned on the housing; wherein the plurality of retainer clips and the plurality of retainer clips slots comprise a clip attachment configuration and a service clip configuration.
 2. The evaporator of claim 1, further comprising a plurality of fan modules.
 3. The evaporator of claim 1, wherein the fan module comprises a fan housing and a fan.
 4. The evaporator of claim 1, wherein the fan module comprises a fan bracket with the plurality of retainer clips thereon.
 5. The evaporator of claim 1, wherein the plurality of retainer clips comprises a substantial U-like shape with a vertical member and a horizontal member.
 6. The evaporator of claim 1, wherein the fan module comprises a locking member and wherein the housing comprises a receiving member sized for the locking member.
 7. The evaporator of claim 6, wherein the receiving member comprises an aperture and an indent.
 8. The evaporator of claim 1, wherein the housing comprises a support rail about a bottom thereof.
 9. The evaporator of claim 8, wherein the support rail comprises a plurality of support rail slots sized therein.
 10. The evaporator of claim 1, wherein the fan module comprises a service clip and wherein the housing comprises a service clip slot.
 11. An evaporator, comprising: a housing; a fan module removably positioned within the housing; a plurality of retainer clips positioned on the fan module; a plurality of retainer clip slots positioned on the housing; a service clip positioned on the fan module; and a service clip slot positioned on the housing; wherein the plurality of retainer clips and the plurality of retainer clips slots comprise a clip attachment configuration and wherein the service clip and the service clip slot comprise a service clip configuration.
 12. The evaporator of claim 11, further comprising a plurality of fan modules.
 13. The evaporator of claim 11, wherein the fan module comprises a fan bracket with the plurality of retainer clips thereon.
 14. The evaporator of claim 11, wherein the fan module comprises a locking member and wherein the housing comprises a receiving member sized for the locking member.
 15. The evaporator of claim 11, wherein the housing comprises a support rail about a bottom thereof.
 16. An evaporator, comprising: a housing; a fan module removably positioned within the housing; a plurality of retainer clips positioned on the fan module; a plurality of retainer clip slots positioned on the housing; a support rail within the housing; and a plurality of support rail slots positioned within the support rail; wherein the plurality of retainer clips and the plurality of retainer clips slots comprise a clip attachment configuration and wherein the plurality of retainer clips and the plurality of support rail slots comprise a service clip configuration.
 17. The evaporator of claim 16, further comprising a plurality of fan modules.
 18. The evaporator of claim 16, wherein the fan module comprises a fan bracket with the plurality of retainer clips thereon.
 19. The evaporator of claim 16, wherein the fan module comprises a locking member and wherein the housing comprises a receiving member sized for the locking member.
 20. The evaporator of claim 16, wherein the fan module comprises a service clip and wherein the housing comprises a service clip slot. 